JP6038114B2 - Ceramic discharge metal halide (CDM) lamp and manufacturing method thereof - Google Patents

Description

  The present invention relates to ceramic discharge metal halide (CDM) lamps, and more particularly to a high power CDM lamp with a reinforced containment assembly and a method of manufacturing the same.

  As energy prices rise, inefficient bulbs are being replaced by energy-saving retrofit bulbs that save power and provide improved lighting. Typical improved replacement bulb types include quartz metal halide (QMH), ceramic discharge metal halide (CDM), and the like. Unfortunately, conventional CDM lamps are limited to specific applications and, as described below, typically cannot be used as a direct replacement for existing lighting systems such as probe-started (lit) ballasts. Furthermore, as CDM lamps increase in power (nominal wattage), in the event of a failure, it is difficult to contain the bulb without adversely affecting the lighting output efficiency in lumens / watt (lm / W) (eg, (As specified by containment tests such as the Overpower American National Standards Institute (ANSI) containment test).

  For high power lamps, high wattage CDM lamps with a rating higher than about 700 watts are not currently available on the market. However, QMH lamps are available with ratings of 750, 1,000 and / or 1,500 watts. In addition, QMH lamps rated at 875, 1,250, 1,650 and 2,000 watts can be used to save energy, but require unique ballasts. For 2,000 watt QMH lamps, these lamps are typically used in commercial areas such as stadiums. A QMH lamp rated at 1000 watts or less typically has a rated life of about 12,000-18,000 hours for vertical operation and a shorter rated life for horizontal operation. However, QMH lamps with a rating greater than 1,000 watts typically have a rated life of between 3,000 and 6,000 hours and are primarily used for sports and stadium lighting. ing. Most conventional lighting systems use probe start ballasts that do not supply high voltage pulses to start the lamps, so in these systems the lamps are spotted with a peak open circuit voltage as low as 622 volts according to ANSI standards. Must arc. In addition, pulse start lamps also exist, but these are typically not interchangeable with probe start lamps (eg, probe start QMH lamps) due to insufficient spacing in the metal parts and the outer jacket where breakdown can occur. Absent. With respect to open luminaires, certain grades of lamps for open luminaires meet ANSI “O” designations and typically use additional containment.

  The present application discloses an illumination system that may be compatible with one or more illumination systems such as probe start, pulse start, closed rated, open rated lamps and the like. These illumination systems may include various types of ballasts such as ANSI ballast codes M47 and M141 for each of the probe and pulse starting systems, as well as lamp types MH1000, MP1000 and MS1000 quartz metal halide types (QMH). However, it is contemplated that other lamps, such as lamps having different rated powers, can also be used with embodiments of the present system. For example, a lamp of 1200 watts or less operating on a QMH 1500 W ballast or a lamp of 620 watts or less operating on a QMH 750 W ballast may be compatible with the system. Further, due to improved characteristics such as lifetime, lighting, efficiency, price and / or multi-system compatibility, the lamp according to embodiments of the present system may be ideal for retrofitting conventional lamps.

  According to one aspect of the system, a ceramic discharge metal halide (CDM) lamp is disclosed. The lamp forms a cylinder and has a first shroud with a first wall defining a first cavity; and is disposed within the first cavity and forms a cylinder and includes a first shroud of the first shroud. A second shroud including a second wall defining a second cavity located within the first cavity; a first coil portion located around at least one of the first and second shrouds; and / or the second cavity. A ceramic arc tube positioned within and having first and second openings and first and second leads, each containing an electrode, and defining a lamp cavity containing a fill. The apparatus may also include another coil portion positioned between the first shroud and the second shroud, in which case the first coil portion is positioned around the first shroud. In addition, the apparatus can include a frame with first and second side members extending on opposite sides of the first and second shrouds. Further, the apparatus can include first and second shroud caps coupled to the side members of the frame and capable of relatively positioning the first and second shrouds. Further, it is contemplated that the lamp according to an embodiment of the present system may further include a coil that can surround one or more components, the frame, and / or the first and / or second shroud. Each of the coils may have a plurality of turns (turns) whose pitch can be constant or variable. Further, each of the coils can have a different pitch, number of turns and material. For example, a coil that is closer to a heat source such as an arc tube may have another material (eg, molybdenum) that may be more resistant to heat than a coil material (eg, nickel) that is further away from the heat source. Can be formed from Further, one or more of the coils can be coupled to the frame at one or more ends.

  With respect to the materials used for the coil, high temperatures, such as temperatures higher than 600 ° C. that can be received even outside the shroud, are “black” in some materials (eg, nickel (Ni) or nickel plated wires). Can occur. Thus, niobium (Nb), tungsten (W), zirconium (Zr) or other materials that are resistant to blackening at such high temperatures, if desired, reduce or completely prevent “blackening”. Can be used for. Further, for one or more internal regions of the shroud, a high temperature resistant material such as molybdenum can be used to form a coil that reduces or completely prevents “blackening”. However, other materials or combinations of materials for the coil are also contemplated.

Further, the fill may include a gas or Penning mixture of 99.5% neon (Ne) and 0.5% argon (Ar). Furthermore, the filling can have a pressure of 100 torr or less. The packing further comprises sodium iodide (NAI), thallium iodide (TlI), calcium iodide (II) (CaI ₂ ), cerium (III) iodide (CeI ₃ ) and manganese iodide (MnI ₂ ). A salt mixture having an iodide selected from can be included. The _{NAI, TlI, CaI 2, CeI} 3 and% by weight of iodide MnI ₂ are each 0.8～3.8,2.3～3.0,82.6～93.8,2.3 In the range of ˜6.8 and 0.8 to 3.8.

  According to another aspect of the system, a method of forming a ceramic discharge metal halide (CDM) lamp is disclosed. The method includes forming a first shroud having a first wall defining a cylinder defining a first cavity; a second wall positioned within the first cavity and defining a cylinder defining a second cavity. Forming a second shroud comprising: positioning a first coil portion around at least one of the first and second shrouds; and / or disposing a ceramic arc tube in the second cavity. The arc tube has first and second openings with first and second openings and electrodes located at the ends, and can define a lamp cavity containing a filling. . Further, the method can further include the step of positioning another coil portion between the first shroud and the second shroud, wherein the first coil portion surrounds the first cylindrical shroud. Located in. Further, the method can include forming a frame with first and second side members extending on opposite sides of the first and second shrouds. Further, the method can include attaching first and second shroud caps to the side members of the frame to relatively position the first and second shrouds.

The method may further comprise the step of filling the lamp cavity with a filling, the filling comprising a gas mixture or Penning mixture of 99.5% neon (Ne) and 0.5% argon (Ar). Have Further, the method can include pressurizing the lamp cavity to a pressure of 100 torr or less. Furthermore, the method, sodium iodide (NAI), thallium iodide (TlI), calcium iodide _(CaI 2), the selected iodides cerium iodide (CeI ₃₎ and iodide manganese (MnI ₂₎ Forming the filler to include a salt mixture including it in the cavity may be included. Furthermore, the method, the filler, the NAI, _TlI, is CaI 2, CeI ₃ and% by weight of iodide MnI _2, respectively, 0.8～3.8,2.3～3.0, Forming steps of 82.6 to 93.8, 2.3 to 6.8, and 0.8 to 3.8.

FIG. 1A is a front view of a portion of a lamp according to an embodiment of the present system. FIG. 1B is a front view of a portion of the lamp shown in FIG. 1A according to an embodiment of the present system. FIG. 2 is a side view of a portion of a lamp according to an embodiment of the present system. FIG. 3 is a sectional view of a part of the lamp taken along line 3-3 in FIG. FIG. 4 is a perspective view of a shroud cap according to an embodiment of the present system. FIG. 5 is a top view showing details of a shroud cap according to an embodiment of the present system. FIG. 6 is a bottom view showing details of a shroud cap according to an embodiment of the present system. FIG. 7A is a side view of a portion of a coil wound around a shroud according to an embodiment of the present system. FIG. 7B is a side view of a portion of a coil wound around a shroud according to an embodiment of the present system. FIG. 7C is a side view of a portion of a coil wound around a shroud according to an embodiment of the present system. FIG. 8 is a cross-sectional view of a portion of an arc tube according to an embodiment of the present system. FIG. 9 is a side view of a lead according to an embodiment of the present system. FIG. 10 is a side view of a lead according to an embodiment of the present system. FIG. 11 is a front view of a portion of a frame according to an embodiment of the present system. FIG. 12 is a side view of a portion of a frame according to an embodiment of the present system. FIG. 13A is a front view of a portion of a lamp according to an embodiment of the present system. 13B is a front view of a portion of the lamp shown in FIG. 13A according to an embodiment of the present system. FIG. 14 is a side view of a portion of a lamp according to an embodiment of the present system. FIG. 15A is a diagram showing an acceptance angle according to an embodiment of the present system. FIG. 15B is a diagram showing an acceptance angle according to an embodiment of the present system. FIG. 16 is a side view of a lamp according to an embodiment of the present system. FIG. 17 is a perspective view of a lamp 1700 according to an embodiment of the present system. FIG. 18 is a graph showing hydrogen iodide (HI) voltage spike versus neon / argon (Ne / Ar) charge pressure for a lamp according to an embodiment of the present system. FIG. 19 is a graph showing start time versus electrode distance (D) × fill pressure (P) (PxD) for a lamp according to an embodiment of the present system. FIG. 20 is a graph showing luminous flux versus time for a CDM lamp according to an embodiment of the present system. FIG. 21 is a graph showing luminous efficiency versus manganese iodide (MnI ₂ ) injection for a lamp arc tube fill according to an embodiment of the present system. FIG. 22 is a graph showing color temperature (CCT) versus cerium iodide (CeI ₃ ) injection for a lamp arc tube fill according to an embodiment of the present system. FIG. 23 is a graph showing the average perceivable color difference (MPCD) vs. CCT for an experimental high watt CDM lamp according to an embodiment of the present system. FIG. 24 is a graph showing the salt range of iodide salt injection for improved results for a lamp according to an embodiment of the present system. FIG. 25 is a chart showing photometric values for nine lamps whose experimental test results are shown in Table 3 according to an embodiment of the present system.

  The present invention will now be described in detail by way of example with reference to the accompanying drawings.

  The following is a description of an illustrative embodiment showing the features and advantages described above and others in conjunction with the drawings described below. In the following description, for purposes of explanation rather than limitation, illustrative details such as architecture, interconnection, technology, and component attributes are provided. However, it will be apparent to one skilled in the art that other embodiments that depart from these details are within the scope of the appended claims. Further, for the sake of clarity, detailed descriptions of well-known devices, circuits, tools, techniques and methods have been omitted so as not to obscure the description of the system. It should also be clearly understood that the drawings are included for illustrative purposes and do not represent the scope of the system. In the accompanying drawings, like reference numbers in different drawings may designate similar elements.

  To simplify the description of the system, as used herein, “operably coupled”, “coupled” and components of these terms are such that devices and / or devices that allow operation according to the system. Or it refers to a connection between parts of the device.

  In order to explain the embodiment of the present system, FIGS. 1, 2 and 3 will be described. 1A and 1B are front views of a portion of a lamp 100 according to an embodiment of the present system. FIG. 2 is a side view of a portion of a lamp according to an embodiment of the present system. FIG. 3 is a cross-sectional view of a portion of the lamp along the line 3-3 in FIG.

  The lamp 100 may include a frame 120 capable of supporting an arc tube 102 and a shroud portion 130. The frame 120 can include one or more extensions 122 (eg, side members), each extending between a near end 121 and a far end 123 of the frame 120. For clarity, it is assumed that the frame 120 is symmetrical and the extensions 122 are mirror images of each other. However, it is also conceivable that the frame is asymmetric and may include, for example, a single extension or extensions that are not mirror images of one another. At the proximal end 121, the frame 120 can be secured to the stem portion (stem portion) 144 using any suitable method, such as a frame clip 142, and the frame clip can be both the stem portion 144 and at least one of the extension portions 122. For example, it can wind around so that friction engagement may arise with respect to each part. The stem portion 144 can be attached to any suitable attachment depending on the type of attachment desired. The frame 120 may include a far end support 125 at the far end 123. The far end support 125 can be supported by a portion of the outer bulb (bulb), and preferably holds the frame 120 in a desired position relative to the outer bulb during use. Accordingly, the far end support portion 125 can include a mounting portion 126 and a disk 124 such as a mica disk. The attachment portion 126 may include a biasing member, and the biasing member may generate a frictional force with respect to the outer bulb, thereby fixing the frame portion 120 to the outer bulb. The disk 124 can be formed from a suitable material, such as mica, and can be shaped and dimensioned to prevent a failed lamp component from remaining in the dome of the lamp.

  A getter, such as getter 118, can be provided to control the environment within the cavity of the outer bulb portion (eg, by absorbing oxygen, moisture, etc.), eg, at least one extension 122 or other of frame 120 It can be applied to the part or to control the environment. Since getters are well known in the prior art, no further description of the getter is given for the sake of brevity.

  Each of the first and second stem leads 112 and 114 can be formed of a suitable conductive material, and the stem 144 is connected to the first and second stem leads 112 and 114 via the stem 144. It can extend so that a seal can be formed around each. The second stem lead 114 can be coupled to the extension 122 of the frame 120 through the frame connection 116. Accordingly, the frame connection 116 can be attached to the frame 120 and / or the second stem lead 114 using any suitable method such as welding, frictional coupling (eg, pressure welding), or the like. However, it is conceivable to allow the second stem lead 114 to be directly coupled to the frame 120. The first stem lead 112 can be coupled to the base lead 110 using any suitable method such as welding, friction coupling, or the like. The frame connection 116 can be flexible and can be formed from a coil spring having multiple turns if desired.

The shroud assembly 130 can include one or more portions such as first and second shroud portions 134 and 136, first and second coils 138 and 140, and a shroud cap 132. The first and / or second shroud portions 134, 136 can have cylindrical tubes made of a suitable material, such as glass (eg, quartz), with a _wall thickness (T _wall ), eg, 2 mm. . In this embodiment, a 1 mm gap is provided between adjacent walls of the first and second shroud portions 134 and 136 to provide space for the coil 140 to be placed around the outer periphery of the second shroud portion 136. Can exist. However, other thicknesses can be considered. For example, the thickness of the first and / or second shroud portions 134, 136 can be the same or different from each other. As such, the first shroud portion 134 can define the cavity 145 and the second shroud portion 136 can define the cavity 147. The second shroud portion 136 may be disposed in the cavity 145 of the first shroud portion 134 such that the first and second shroud portions 134 and 136 are positioned concentrically with each other. However, it is also conceivable that the first and second shroud portions 134 and 136 can be other than those that are concentrically positioned with respect to each other. Thus, for example, the first and second shroud portions 134 and 136 can be offset with respect to their major axes and / or with respect to these other axes. The first and second shroud portions 134 and 136 may have lengths L _s1 and L _s2 , respectively. These lengths can be equal to each other, shown as a shroud length L _s in common for clarity. However, it is also conceivable that the lengths L _s1 and L _s2 can be different from each other. The shroud assembly 130 may further include one or more wire coils, such as first and second coils 138 and 140, each of which forms a helix with multiple turns (N _t ). Etc. (eg, molybdenum (Mo or Moly) wire, nickel plated stainless steel wire, etc.). The N _t of the first and second wire coils 138 and 140 can be the same or different from each other. The first coil 138 can be located around the first shroud portion 134, while the second coil 140 is around the second shroud portion 136 and the coil is between the first and second shroud portions 134 and 136. Thus, the first shroud portion 134 can be disposed so as to be within the cavity 145. It is further contemplated that the first and second coils may be formed from materials other than wires, such as flat, stamped and / or etched, metal with openings. The coil is preferably formed from a conductive material. However, it is contemplated that high temperature fibers such as glass fibers may be used in embodiments of the present system.

  The shroud cap 132 can be attached to one or more of the extensions 122 of the frame 120 using any suitable method, such as a tab (eg, capable of friction fitting, etc.), welding, etc. The first and second shroud parts 134 and 136 and / or the first and second coils 138 and 140 are positioned.

  The arc tube 102 may be located in the cavity 147 of the second shroud portion 136 (located in the cavity 145 of the first shroud portion 134) and the tube 150 and the first and second leads 104 and 106. Can be included. Tubing 150 defines a cavity with first and second openings through which corresponding ones of the first and second leads penetrate and are sealed using any suitable method, such as a frit ring. Can do. The second lead 106 can be coupled to the base lead 110 via the connection 108, while the first lead 104 is coupled to the frame 120 via the connection 109 and / or the far end lead 146. be able to.

  The far end lead 146 can pass through the opening in the corresponding shroud cap 132, while the base lead 110 can pass through the opening in the corresponding shroud cap 132 and is insulated from the cap by the insulator 133. Can be insulated. The insulator 133 can be formed of an appropriate material such as quartz glass capable of forming a cylindrical tube or the like. The opposite potential portions preferably have sufficient spacing, for example, and in some embodiments a 9 mm spacing may be sufficient. Of course, other intervals are possible according to embodiments of the system.

FIG. 2 is a side view of a portion of a lamp 100 according to an embodiment of the present system, extending from the center 103 of the arc tube 102 (or the center of the illumination area or volume) and having a side portion of the shroud assembly 130. It shows the acceptance angle (A _A : acceptance angle; half of the opening angle) that can be defined as the angle that intersects the perimeter or edge. Therefore, A _A is larger as L _S is longer, and conversely, A _A is smaller as L _S is shorter. The acceptance angle will be described later with reference to FIGS. 15A and 15B.

  As illustratively shown in FIG. 3, the shroud cap 132 can be attached to one or more of the extensions 122 of the frame 120 using any suitable method, such as a mounting tab 141, which can be attached to the frame assembly 120. The adjacent extension 122 can be frictionally engaged. The first and second shroud portions 134 and 136 and / or the first and second coils 138 and 140 are each held in place by the tab 139 of the corresponding shroud cap 132. Further, for the sake of clarity, with respect to shroud cap 132, these shroud caps are assumed to be identical. However, the shroud caps may be different from each other.

  FIG. 4 is a perspective view of a shroud cap 132 according to an embodiment of the present system. The shroud cap 132 can be formed from a suitable material, such as stainless steel or nickel plated steel, and can be stamped to form the openings 137, tabs 139, and / or mounting tabs 141. FIG. 5 is a top view showing details of the shroud cap 132 according to an embodiment of the present system. FIG. 6 is a bottom view showing details of the shroud cap 132 according to an embodiment of the present system.

  FIG. 7A is a side view of a portion of a coil 702A wound around a shroud 736A according to an embodiment of the present system. The arc tube 750A is disposed in the shroud 736A. Coil 702A may have a varying pitch that may increase toward the central portion of shroud 736A.

  FIG. 7B is a side view of a portion of a coil 702B wound around a shroud 736B according to an embodiment of the present system. The arc tube 750B is disposed in the shroud 736B. The coil 702B can have a constant pitch.

  FIG. 7C is a side view of a portion of coil 702C wound around shroud 736C according to an embodiment of the present system. The arc tube 750C is disposed in the shroud 736C. Coil 702C may have a varying pitch that may decrease toward the central portion of shroud 736C. Thus, the spacing or pitch between adjacent turns of the coil (or coils) can be increased towards the central portion of the shroud. During a containment test in which the lamp is operated under test conditions that destroy one or more of the shrouds, the shroud is more layered in the central portion of the shroud, which is the region located closest to the central portion of the arc tube. It has been found that it breaks into smaller pieces and breaks into larger pieces at the end of the shroud further away from the arc tube center. Therefore, a smaller coil pitch is used in the portion of the coil that surrounds the central region of the shroud to contain smaller shattered pieces of broken shroud that are expected to be located around the central region of the shroud. be able to. Similarly, a larger coil pitch can be used for such portions of the coil to contain larger pieces of broken shroud that are expected to be located in the end region of the shroud.

  Further, with respect to the diameter of the shroud, the size of the broken shroud fragments increases as the distance from the shroud increases. Conversely, broken shroud fragments decrease in size from the outside of the shroud to the inside shroud and from the ends of the shrouds toward the center. Thus, in certain embodiments, the pitch of the coil can be increased as the diameter of the shroud around which the coil is placed increases (while the arc tube remains a constant size).

  Thus, in some embodiments, the pitch or spacing between the coils can be adjusted for containment purposes. For example, according to an embodiment of the system, the shroud assembly can include inner and outer shrouds, with an inner coil disposed around the inner shroud and an outer coil disposed around the outer shroud. . The inner coil can have N turns, while the outer coil can have M turns, thus forming a shroud with an (N + M) configuration. For example, if the inner and outer coils each have 5 turns, the shroud can have a (5 + 5) configuration. Thus, assuming that the shroud can break into differently sized pieces in different parts of the shroud, the winding pitch or spacing in the coil part, especially around the part around the arc tube center in the shroud. Can be increased to improve destruction protection. For example, according to an embodiment of the system, the shroud has a (5 + 5) configuration with a winding pitch of about 30 mm, a (10 + 10) configuration with a winding pitch of about 15 mm, and a winding It can have a (15 + 15) configuration with a pitch between about 10 mm. The pitch can remain constant or can be varied. In addition, additional turns can be provided to account for coil sag that may occur during use. However, other winding numbers and / or pitches are also conceivable.

Furthermore, with respect to the number of turns _Nc , the number of turns per inch or the number of turns per unit length, such as pitch, can be constant and / or non-constant (eg, changing). For example, for a fixed number of turns, there may be 6 turns per inch, while for a non-constant number of turns, there may be 6 turns per inch for the first half inch and for the next half inch. There can be 12 turns per inch.

FIG. 8 is a cross-sectional view of a portion of an arc tube 800 according to an embodiment of the present system. The arc tube 800 may be similar to the arc tube 102, and may include a main body 802 and a lead wire 804. The body portion 802 can define a cavity 806 with an opening 805. The lead wire 804 can extend through a corresponding opening 805 in the opening 805 in the main body 802. The cavity 806 can include a fill 813, which can include one or more of mercury 815, salt 817 (eg, a salt mixture), and chemical 819. Salt 817 can include any suitable salt as described herein, for example, iodides of sodium (Na), thallium (Tl), calcium (Ca), cerium (Ce) and manganese (Mn). Can be included. However, other materials such as dysprosium (Dy), thulium (Tm), holmium (Ho), lithium (Li), and indium (In) or other materials can also be suitably applied. For example, it is contemplated that other suitable salts can include iodides such as zirconium (Zr), praseodymium (Pr), and scandium (Sc). Each of the leads 804 can have a near end 820 and a far end 822 and an electrode 808 at the far end 822. Further, one or more of the leads 804 can include a crimp 825 positioned between the near end 820 and the far end 822. The crimping portion can be provided to set the distance between the electrodes with respect to the main body. To seal the cavity 806, a frit 810 can be disposed in the wall of the opening 805 and the corresponding lead 804. Far end 822, it is possible to place a distance _{L E} about 16~18mm each other, can be separated by crimping unit distance _{L C} is the crimping portion 825, piezoelectric attaching portion a distance of about 30.5 mm ± Although it can be 0.1 mm, other dimensions are also conceivable. The cermet 810 can have a length _{L F,} but the length is can this be about 16 mm ± 0.1 mm, other dimensions are contemplated. Further, the crimp 825 can have a length L _CC , which can be about 1.3 mm ± 0.1 mm, although other dimensions are also contemplated.

  FIG. 9 is a side view of a lead 804 according to an embodiment of the present system. Lead wire 804 has portions 902, 904, and 906, which correspond to a niobium (Nb) portion, a cermet portion, and an electrode portion, respectively. The crimping portion 825 can have an outer diameter larger than the inner diameter of the arc tube opening (see, for example, the opening 805) through which the lead wire 804 extends. The lead wire can couple the Nb part 902 and the cermet part 904 to each other.

  FIG. 10 is a side view of a lead 1000 according to an embodiment of the present system. The lead can include portions 1002, 1004, and 1006, which can correspond to an Nb portion, a cermet portion, and an electrode portion, respectively.

  FIG. 11 is a front view of the frame 120 according to an embodiment of the present system. The frame clip 142 can include a complete or partial loop and can be attached to the frame 120 using any suitable method such as welding, friction fitting, or the like. FIG. 12 is a side view of an example portion of a frame 120 according to an embodiment of the present system.

  FIG. 13A is a front view of a portion of a lamp 1300 according to an embodiment of the present system. FIG. 13B is a front view of a portion of the lamp shown in FIG. 13A according to an embodiment of the present system.

  Referring to FIG. 13A, the lamp 1300 is substantially similar to the lamp 100. However, the lamp 1300 can have different shroud portions 1330. The shroud portion 1330 can include shroud caps 1332 and 1335, which are different from each other and connected to the frame 1320 to support one or more shrouds, such as first and second shrouds 1334 and 1336. Can do. As shown in the detailed view of FIG. 13B, the first coil 1338 can be disposed around the first shroud 1334, while the second coil 1340 can be disposed around the second shroud 1336. FIG. 13B shows a portion of the first and second shrouds 1334 and 1336 and the first and second coils 1338 and 1340 according to one embodiment of the system. Returning to FIG. 13A, the arc tube 1302 may include first and second leads 1304 and 1306. The first lead 1304 can be coupled to the frame 1320 via the connector 1309 and the cross reinforcement 1346, while the second lead 1306 can be coupled to the first trunk lead 1312 via the connector 1310. it can. The connection body 1310 can pass through the opening of the first shroud cap 1335. The shroud cap 1335 can include a tab 1341, which can frictionally engage the frame 1320 and weld to the frame 1320 to hold the shroud cap 1335 in place relative to the frame 1320. You can also The shroud cap 1335 can be a partial shroud cap and can hold a portion of the first and second shrouds 1334 and 1336. The frame 1320 can be coupled via a frame connector 1314 to a second trunk lead 1314 that can penetrate the trunk 1344.

  FIG. 14 is a side view of a portion of a lamp 1300 according to an embodiment of the present system.

15A and 15B are diagrams showing acceptance angles according to an embodiment of the present system. Referring to FIG. 15A, arc tube 1502A is mounted in a cavity of shroud assembly 1530A having a length L _SA and is held in place by an opposing shroud cap 1532A having an outer periphery defining a diameter Od _SA . Acceptance angle A _AA is shown as having an apex at approximately the midpoint of arc tube 1502A and intersecting the outer periphery of shroud cap 1532A. Referring to FIG. 15B, arc tube 1502B is mounted in a cavity of shroud assembly 1530B having a length L _SB and held in place by opposing shroud caps 1532B having an outer periphery that defines diameter Od _SB . Acceptance angle A _AB is shown as having an apex at approximately the midpoint of arc tube 1502B and intersecting the outer periphery of shroud cap 1532B. For clarity, it is assumed that Od _SA and Od _SB are identical. Thus, it can be seen that the acceptance angle A _AX is related to the distance between corresponding opposing shroud caps 1532X that is approximately equal to the length L _SX of the shroud 1530X. Therefore, referring to FIGS. 15A and 15B, the longer L _SX is, the larger A _AX is. Conversely, the smaller L _SX is, the smaller A _AX is. In order to improve the illumination efficiency, it is preferable that the acceptance angle is as large as possible.

  The shroud length requires extra material and does not become too large to increase weight and cost, thereby improving (eg maximizing) the acceptance angle and thus increasing the lighting efficiency. Can be selected. For example, to control the acceptance angle, a larger diameter shroud may need to be longer to have the same or similar acceptance angle that a smaller diameter shroud may have. Accordingly, it may be desirable to reduce (eg, minimize) the shroud diameter so that the length can be reduced to save material and reduce costs.

  According to embodiments of the present system (eg, 830W lamp), the outer diameter (Od) of the arc tube can be 28 mm, while the inner shroud can have an inner diameter (Id) of about 34 mm, thereby A gap of about 3 mm surrounding the arc tube is provided. This gap will be sufficient to prevent overheating of the arc tube and to allow for misalignments that may occur during mounting and transportation and handling. The thickness of the shroud can depend on the containment requirements, and in this embodiment, both shrouds (first and second shrouds) can be about 2 mm thick (eg, having a wall thickness) , The overall gap between the shrouds can be about 1 mm, leaving space for inner containment coils and shroud dimension variations. The first (eg, outer) shroud may have an Id of about 40 mm and an Od of about 44 mm. Further, with respect to length, the first and / or second shroud can have a length of about 150 mm. However, other dimensions are also conceivable. For example, a smaller diameter arc tube can have a shorter length and a smaller diameter, while a larger diameter arc tube can have a larger diameter and a longer length shroud.

  FIG. 16 is a side view of a lamp 1600 according to an embodiment of the system, and FIG. 17 is a perspective view of a lamp 1700 according to an embodiment of the system. For example, the lamp 1600 can include an outer bulb 1604 having a cavity 1605 in which the lamp assembly 1601 is stored. The cavity 1605 can be sealed with a base 1616 suitable for mounting in a desired mounting socket such as an E or O type mounting socket. The base 1616 can include a contact 1620 that is electrically coupled to one of the first and second trunk leads 1612 and 1614. A sealer such as an insulator 1618 and / or a Vitrite insulator can insulate the contact 1620 from the base 1616. Thus, for example, the lamp 1600 can provide an improved 830 W energy saving replacement lamp for a conventional QMH 1000 W system.

[Containment]
In order to pass a containment test, such as an ANSI containment test for an open luminaire lamp, it has been found that a specific installation procedure is desirable. This becomes more true as the rated power of the lamp increases. Thus, here, for some open luminaire lamps, a comparison of available energy during lamp operation (eg, operating energy (EO)) and containment testing is shown according to embodiments of the system, Ensure that acceptable containment methods are understood. With respect to the energy used during lamp operation, this energy can be referred to as operating energy (OE) and can be calculated from the product PxV. Here, P is the operating pressure and V is the arc tube volume. The operating pressure P can also be estimated from the amount of Hg injection (eg in mg) divided by the arc tube volume in cm ³ of the arc tube, thus canceling the arc tube volume. When scaled to joule units, the lamp OE can simply (and generally) be related to the mercury dose defined in Equation 1 below:
Operating energy (J) = 0.1xHg (mg) ………… Formula 1

Table 1 shows the containment methods that can be set according to the operating energy and voltage for several lamp types based on Equation 1 and the operating energy determined for the lamp type according to the present system / lamp implementation. For example, certain high operating energy (eg, large wattage) lamps have operating energy that can be 5 to 60 times greater than the operating energy of lower voltage and wattage lamps. Thus, the high operating energy lamp may include more containment “elements” than the lamps with lower operating energy in Table 1, which shows the nominal voltage and operating energy for the virtual lamp x (x-CDM400HPSRW and x− See CDM830W).


For example, during a containment test, such as an ANSI containment test, the lamp is operated over a period of about 5 seconds at 3-4 times the rated power, which can rupture the arc tube. However, according to the present system, a lamp with two concentric quartz shrouds and two end caps (eg, shroud caps), each wrapped with molybdenum wire, prevents the component from popping out of the end of the shroud. Thus preventing the arc tube ruptured by the containment test of this embodiment. Thus, a lamp using the containment method according to the present system can pass the applicable containment test. According to an embodiment of the system, the concentric quartz shrouds can each have a wall thickness of 2 mm.

  Returning to FIGS. 15A and 15B, the lamp luminous efficiency of a particular lamp of a particular wattage is reduced based on the proximity to the light source, such as the arc tube 1502, by the shroud cap of the shroud portion 1530 and the added coil. To obtain (eg, from about 103 lm / W to about 89 lm / W). Therefore, by increasing the length of the shroud (for example, from 100 mm to 150 mm), the lamp luminous efficiency can be returned to, for example, 100 lm / W. Thus, although some loss due to the use of quartz shrouds, coils and / or shroud caps may be unavoidable, the illumination luminous efficiency of the lamp according to embodiments of the system should be controlled to exceed about 90-100 lm / W. Can do.

[Filling]
Containment is only one aspect of a CDM lamp with this system. When lamps such as CDM lamps are new, they are subject to high re-ignition voltage spikes (hereinafter voltage spikes) that can cause the lamps to turn off (eg, off) during the first hour of operation. This can be a problem when using a lighter gas to fill the arc tube of the lamp. For example, the voltage spike can be higher when using argon (Ar) than krypton (Kr) or xenon (Xe), and even higher when using neon (Ne) than Ar. Voltage spikes can be the result of hydrogen contamination and / or iodide contamination and can be referred to as hydrogen iodide or HI voltage spikes (both hereinafter referred to as spikes) and are well known in the prior art. . Minimizing spikes can be a matter of increasing volume and pressure; US Pat. No. 6,555,962 by Jackson et al., Named ceramic metal halide lamp with intermediate aspect ratio (see the contents of that patent) Incorporated herein). However, in the case of a lamp to be started on a magnetic ballast without high voltage pulses, the pressure in the lamp cannot be excessively high and the product of the interelectrode gap and pressure (PxD) is well known in the prior art. It must be minimized as defined by Paschen's law. These two variables compete in that reducing the breakdown voltage with low pressure can also increase the HI spike voltage and cause the lamp to repeat during start-up. Accordingly, lamps according to embodiments of the present system can use fillers as described below to overcome these limitations.

  FIG. 18 is a graph showing HI voltage spike versus Ne / Ar fill pressure for a lamp according to the system, and FIG. 19 shows start time versus interelectrode gap × fill pressure (PxD) for a lamp according to an embodiment of the system. It is a graph to show. Referring to FIGS. 18 and 19, a 99.5% Ne and 0.5% Ar charge gas mixture (eg, Penning mixture) with a fill pressure of 100 torr or less meets ANSI maximum voltage spike requirements (FIG. 18). At the same time, it was found that the start time requirement was met at a minimum open circuit voltage of 622 volts for ANSI M47 magnetic 1000 watt QMH ballast when the interelectrode gap distance was set to 18 mm, for example (see FIG. 19). . However, other distances are possible.

  The lamp voltage according to embodiments of the system can be adjusted to provide an average lamp operating power of 830 watts in most commercial CWA ballasts. Thus, a lamp according to the present system can be an ideal replacement lamp for a conventional QMH lamp with a higher rated power (eg 1000 watts). Furthermore, since the ceramic lamp of the present system has no or little Na loss compared to the quartz lamp, the ceramic lamp of the present system can exhibit better light flux maintenance than the conventional QMH lamp. As such, the initial lower luminous flux of the ceramic MH lamp as compared to the QMH lamp can be offset by better luminous flux performance during the lifetime as shown in FIG. FIG. 20 is a graph showing luminous flux versus time for a CDM lamp rated at 830 W and an equivalent QMH1000 W lamp according to the present system.

FIG. 21 is a graph illustrating the luminous efficiency of a lamp according to an embodiment of the present system versus the amount of MnI _{2 in the} arc tube fill. The filling can include salts suitable for ceramic lamps, such as salts based on iodides of Na, Tl, Ca, Ce and Mn, but as known in the prior art, Dy, Tm, Ho. Other materials such as Li, In and / or others may also be included. However, as shown in FIG. 21, a critical amount of Mn is found and should not be exceeded in certain embodiments, otherwise the luminous efficiency can be significantly reduced as shown in FIG. For example, in the above MnI ₂ to about 2.7 mg, efficiency 10~15lm / W
It is observed that it is only reduced. This may be due to self-absorption, for example. However, even if the critical amount of Mn is exceeded, the blackening of the arc tube according to embodiments of the present system is negligible or nonexistent.

FIG. 22 is a graph showing the color temperature (CCT) versus cerium iodide (CeI ₃ ) injection rate for the lamp fill of a lamp according to an embodiment of the system, and FIG. 23 is an experimental high according to an embodiment of the system. FIG. 6 is a graph showing average perceptible color difference (MPCD) vs. CCT for a wattage CDM lamp. Regarding color temperature, color temperature can be affected by several factors, but as shown in FIG. 22, the color temperature is mainly affected by the amount of CeI ₃ in the arc tube of the lamp according to this system embodiment. I knew I would get it.

While it may be desirable to operate the lamp at a color temperature of about 4000K (eg, a “4K” lamp), a CCT range between 3500K and 4400K can also be considered a “4K” lamp. The selected CCT value is a measure of how much the color coordinates are above (eg, expressed as a positive value) or below (eg, expressed as a negative value) from the black body line. It has been found that it can have a strong correlation with certain MPCD values. It would be desirable to fall within a range of ± 15 points around zero. This means that the CCT is in the range of 3200K to 3800K as shown in FIG. Thus, according to some embodiments of the system, the CeI ₃ infusion weight can be in the range of about 1.5 mg to 4.5 mg. However, as illustrated, other ranges can also be suitably applied.

FIG. 24 is a graph showing the salt range of iodide salt injection to obtain improved results for a lamp according to an embodiment of the present system. In addition, Table 2 below shows the range of salt in weight percent that can produce improved results for lamps according to embodiments of the present system. However, it is contemplated that other types and / or ranges of salt mixtures can be suitably applied.

Table 3 below shows an experiment on a lamp (for example, n = 14 lamps) having an iodide salt variation within the design range shown in Table 2 and having a containment structure according to an embodiment of the present system. Results are shown. For example, according to an embodiment of the present system, the salts of these lamps are roughly sodium iodide (NaI) = 1.0 wt%, thallium iodide (TiI) = 2.6 wt%, calcium iodide ( It can have a mixture of CaI ₂ ) = 92.5 wt%, CeI ₃ = 2.6 wt% and manganese iodide (MnI ₂ ) = 1.3 wt%. However, other mixtures are also conceivable.

FIG. 25 is a chart showing photometric results for the 14 lamps described above, the experimental results of which are shown in Table 3 below according to an embodiment of the present system. These lamps may correspond to, for example, 830 W or 830 watt lamps (see, for example, the CDM830W lamp in Table 1) and are equipped with arc tubes, double coils (or coils) and shroud caps (eg, caps) A heavy quartz shroud (eg, a sleeve), a double frame for support, and a quartz insulator that insulates the electrical leads from the opposite potential. The lamp may include features and / or characteristics that may correspond to the lamps shown in FIGS.

Table 3 refers to CIE chromaticity coordinates.

  According to the manufacturing method relating to the embodiment of the present system, the coil can be wound around the inner shroud during the first operation (step). Then, during a second operation, the inner shroud and coil combination can be inserted into the outer shroud pre-wound with the coil, or after insertion of the inner shroud into the outer shroud. Are wound to form a double shroud assembly. Then, during the third operation, the lamp parts can be placed in an assembly fixture for final assembly. Accordingly, the frame, shroud, arc tube and arc tube connection piece, and end cap can be placed within the assembly fixture, for example, in the order listed. However, other orders are also conceivable. During the fourth operation, it is conceivable that the parts held from the assembly and fixing country are welded together to join adjacent parts. The assembly fixture can then be removed from the assembly during a fifth operation. During the sixth operation, components such as getters, outermost coils (if provided), mica disks, and / or upper dome springs can be attached to the frame using any suitable method such as welding. Then, during the seventh operation, a lamp assembly process can be performed to seal the frame and components attached to the frame within an outer bulb (which may include a mounting).

Accordingly, an energy saving CDM lamp comprising a probe-started QMH 1000W ballast (eg, ANSI code M47 ballast) and / or a pulse-started QMH 1000
It may be compatible with ballasts designed for other types of lamps such as W ballast (eg ANSI code M141 ballast) (eg start and operate with such ballast) and both open or sealed There is provided a lamp that can include a protected “O” rating that operates within a luminaire. As such, the lamps of this system can operate as an improved replacement lamp in conventional systems such as the QMH 1000 Watt system and can operate at 830 W when operated under nominal conditions. , Conventional 1000W QM
A 17% power saving can be achieved for the H lamp. In addition, the CDM lamp of the present system can operate at other wattages, such as lower and / or higher wattage than the examples shown here. For example, a lamp according to an embodiment of the present system is a conventional QMH 7
50, 875, 1250, 1500, 1650 and 2000W lamps can be provided for retrofitting. However, it is contemplated that lamps according to embodiments of the present system may be provided to retrofit other lamp types and / or rated power.

Thus, the system is a high power ceramic discharge metal halide (CDM) lamp and manufacturing method, method and system compatible with conventional ballasts such as probe-initiated magnetic ballasts designed for 1000 watt quartz metal halide (QMH) lamps. Is provided (e.g., starting and / or operating). The QMH lamp has a nominal voltage of 265 volts (compared to 135 volts for a medium power lamp) and a power factor greater than 0.90. The system provides a CDM lamp that can have, for example, a power factor of less than 0.85 and a voltage of less than 240 volts to operate with energy saving power of 820-850 watts on a QMH 1000 watt magnetic system. When compared to conventional QMH equivalents such as 1000 Watt QMH bulbs, the light output starts low over the lifetime of the CDM lamp in this system, but due to the excellent luminous flux maintenance and 30% -70% longer life of the ceramic lamp Ends in a higher state. As a further advantage, a lamp according to the present system can include an arc tube containment that can be used in an open luminaire and can improve the light output from the arc tube of the lamp.

  Other variations of the system can be easily conceived by those skilled in the art and are covered by the claims that follow.

  Finally, the above description is intended merely to illustrate the present system and should not be construed to limit the appended claims to any particular embodiment or group of embodiments. Thus, while the present system has been described with reference to exemplary embodiments, those skilled in the art will recognize that a number of systems can be used without departing from the intended spirit and scope of the present system as set forth in the claims below. It should be understood that modifications and alternative embodiments can be envisaged. Further, the section headings included herein are intended to facilitate review and are not intended to limit the scope of the system. The specification and drawings are accordingly to be regarded in an illustrative manner and are not intended to limit the scope of the appended claims.

When interpreting the appended claims,
a) the word “comprising” does not exclude the presence of elements or steps other than those listed in a given claim; b) a singular element may be a plurality of such elements; Does not exclude the existence of
c) any reference signs in the claims do not limit the scope of such claims;
d) several “means” may be represented by the same item or configuration or function implemented by hardware or software;
e) any of the disclosed components can include a hardware portion (eg, including individual or integrated electronic circuitry), a software portion (eg, a computer program) and some combination thereof;
f) The term “plurality” of components includes the components recited in more than one claim and is not meant to imply any particular scope of components. That is, the plurality of components may be as few as two components, and may include an infinite number of components.
Should be understood.

Claims (16)

A first shroud having a first wall defining a cylinder defining a first cavity;
A second shroud having a second wall positioned within the first cavity and defining a cylinder defining a second cavity located within the first cavity of the first shroud;
A first coil which is located in ambient of said first sheet shroud,
A ceramic arc tube positioned within the second cavity and having first and second openings and first and second leads and defining a lamp cavity containing a filling;
A ceramic discharge metal halide (CDM) lamp having: The lamp of claim 1 that further to have a second coil which is located between the first shroud and the second shroud.   The lamp of claim 1, further comprising a frame with first and second side members extending to opposite sides of the first and second shrouds.   The lamp of claim 3, further comprising first and second shroud caps coupled to the first and second side members of the frame and for relatively positioning the first and second shrouds.   The lamp of claim 1, wherein the fill comprises a gas or Penning mixture of 99.5% neon (Ne) and 0.5% argon (Ar).   The lamp of claim 5, wherein the fill has a pressure of 100 torr or less. The packings, sodium iodide (NAI), thallium iodide (TlI), calcium iodide _(CaI 2), including the selected iodides cerium iodide (CeI ₃₎ and iodide manganese (MnI ₂₎ The lamp of claim 5, further comprising a salt mixture. The NAI, _TlI, is CaI 2, CeI ₃ and% by weight of iodide MnI _2, respectively, 0.8～3.8,2.3～3.0,82.6～93.8,2.3 The lamp of claim 7 in the range of ~ 6.8 and 0.8-3.8. A method of forming a ceramic discharge metal halide (CDM) lamp comprising:
Forming a first shroud having a first wall defining a cylinder defining a first cavity;
Forming a second shroud having a second wall positioned within the first cavity and defining a cylinder defining a second cavity;
A step of positioning the first coil to ambient of said first sheet shroud,
Disposing a ceramic arc tube within the second cavity defining first and second openings and first and second leads and defining a lamp cavity containing a fill;
Having a method. The method of claim 9 that further to have the step of positioning a second coil between the second shroud and the first shroud.   The method of claim 9, further comprising forming a frame with first and second side members extending on opposite sides of the first and second shrouds.   The method of claim 11, further comprising attaching first and second shroud caps to the side members of the frame to relatively position the first and second shrouds.   10. The method of claim 9, further comprising the step of filling the lamp cavity with a filling, the filling comprising a gas mixture or Penning mixture of 99.5% neon (Ne) and 0.5% argon (Ar). The method described.   The method of claim 9, further comprising pressurizing the lamp cavity to a pressure of 100 torr or less. Said filler, sodium iodide (NAI), thallium iodide (TlI), calcium iodide _(CaI 2), including the selected iodides cerium iodide (CeI ₃₎ and iodide manganese (MnI ₂₎ The method of claim 9, further comprising forming a salt mixture for inclusion in the cavity. The filler, the NAI, _TlI, is CaI 2, CeI ₃ and% by weight of iodide MnI _2, respectively, 0.8～3.8,2.3～3.0,82.6～93. The method of claim 15, further comprising forming to be in the range of 8, 2.3 to 6.8 and 0.8 to 3.8.